Yamaha AG200F (2003) Supplementary Service Manual
AG200F
SUPPLEMENTARY
SERVICE MANUAL
2003
3GX-AE2
AG200F 2003
SUPPLEMENTARY
SERVICE MANUAL
©2002 by Yamaha Motor Co., Ltd.
First Edition, March 2002
All rights reserved.
Any reprinting or unauthorized use with-
out the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
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FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
AG200F 2003. For complete service information procedures it is necessary to use this Supplementary
Service Manual together with the following manual.
AG200F ’97 SERVICE MANUAL: 3GX-AE1
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NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
w Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person checking or repairing the motorcycle.
cC A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
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SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1 to 8 indicate the subject of each
chapter.
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Engine
5 Carburetor(s)
6 Chassis
7 Electrical system
8 Troubleshooting
Symbols 9 to y indicate the following.
9 Serviceable with engine mounted
0 Filling fluid
q Lubricant
w Special tool
e Tightening torque
r Wear limit, clearance
t Engine speed
y Electrical data
Symbols u to s in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
u Engine oil
i Gear oil
o Molybdenum-disulfide oil
p Wheel-bearing grease
a Lithium-soap-based grease
s Molybdenum-disulfide grease
Symbols d to f in the exploded diagrams indi-
cate the following.
d Apply locking agent (LOCTITE®)
f Replace the part
12
34
56
78
90
qw
er
ty
ui o
pas
df
GEN
INFO
SPEC
CHK
ADJ
ENG
CARB CHAS
ELEC
TRBL
SHTG
LT
New
CONTENTS
SPECIFICATIONS...................................................................................................1
GENERAL SPECIFICATIONS ..........................................................................1
MAINTENANCE SPECIFICATIONS .................................................................2
CHASSIS .....................................................................................................2
ELECTRICAL...............................................................................................2
TIGHTENING TORQUES..................................................................................3
ENGINE .......................................................................................................3
CABLE ROUTING.............................................................................................4
PERIODIC CHECKS AND ADJUSTMENTS...........................................................8
INTRODUCTION ...............................................................................................8
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS.......................8
ELECTRICAL........................................................................................................10
IGNITION SYSTEM .........................................................................................10
CIRCUIT DIAGRAM ..................................................................................10
TROUBLESHOOTING ..............................................................................11
AG200F 2002 WIRING DIAGRAM
– 1 –
SPEC
GENERAL SPECIFICATIONS
Model AG200F
Model code: 3GXF
Engine:
Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 0.196 L (196 cm
3
)
Bore × stroke 67.0 × 55.7 mm
Compression ratio 9.5 : 1
Compression pressure (STD)
900 kPa (9.0 kg/cm2, 130.5 psi) at 1,000 r/min
Starting system Electric and kick starter
Lubrication system: Wet sump
Chassis:
Frame type Diamond
Caster angle 27.42°
Trail 87 mm
Tire:
Type With tube
Size front 80/100-21 51M
rear 4.10-18 59M
Manufacturer front IRC
rear IRC
Type front VE-32
rear FARM SPECIAL - Z2
Tire pressure (cold tire):
Maximum load-except motorcycle 112 kg
Loading condition A * 0~112 kg
(off road riding)
front 120 kPa (1.2 kgf/cm
2
, 17.4 psi)
rear 150 kPa (1.5 kgf/cm
2
, 21.8 psi)
Electrical:
Ignition system DC-CDI
Generator system AC magneto
Battery type GT6B-3
Battery capacity 12V 6 Ah
*Load is the total weight of cargo, rider, passenger, and accessories.
SPECIFICATIONS
GENERAL SPECIFICATIONS
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